Oil Pressure Line For Turbocharger
Removing And Installing Oil Pressure Line For Turbocharger
Tools
Technical values
Preliminary work
Overview of lines
1. Remove charge air cooler.
DANGER:
Parts of the exhaust system become extremely hot.
- Danger of burns
- Permanent scarring of the skin
- Do not begin work until the exhaust system has cooled down completely.
- If it is imperative that you work on the hot exhaust system, ensure that you wear fire-resistant and heat-resistant protective gear.
2. Remove rear silencer
3. Disconnect cable plug on electronic adjuster.
4. Loosen intake manifold.
4.1. Cylinder bank 1-3: unscrew one M6 hexagon nut -1- on the guide plate and two M6 Torx screws -arrows- on the turbocharger.
4.2. Pull off intake manifold at the connection piece and take it out of the bracket in the engine compartment. Pull off cable plug on electronic adjuster.
4.3. Cylinder bank 4-6: unscrew two M6 Torx screws -arrows-.
4.4. Pull off cable plug on electronic adjuster -1 -. Pull off intake manifold at the connection piece and take it out of the bracket in the engine compartment.
5. Replace O-rings on the relevant intake manifold, clean sealing faces carefully.
Removing oil pressure line
Removing oil pressure line - cylinder bank 1-3
1. Loosen the vacuum line for the brake booster. Pull grey circlip and loosen quick-fit connection.
2. Slide intake manifold line out of the support in the engine compartment and turn it to one side.
3. Disconnect cable plug on camshaft adjustment valve.
4. Remove camshaft adjustment valve.
4.1. Unscrew two M6 Torx screws and carefully pull off the valve. Close off the valve bore to prevent dirt from getting in.
5. Unscrew upper M6 screw -2- on oil pressure line -1-.
Tool recommendation: 1/4-inch ratchet, long extension, joint and Torx insert T30 - Oil pressure line on cylinder bank 1-3, upper.
6. Remove cover plate. Unscrew two M6 Torx screws and take off cover plate.
7. Pull off cable plug on ignition coil for cylinder 1, hall sender and valve lift adjustment valve.
8. Loosen ground strap on camshaft housing cover and rubber-coated holding clamp for oil pressure line -1-
8.1. Unscrew one M6 Torx screw on each -2 and 3-.
CAUTION:
Mixing fluids
- Risk of damage to components
- Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).
9. Loosen three lines on the turbocharger.
- Item 1: Supply line to turbocharger oil tank.
- Item 2: Lower coolant line.
- Item 3: Upper coolant line.
9.1. Loosen line to turbocharger oil tank. Unscrew one M6 Torx screw, pull off line and close off bore -3-.
9.2. Loosen lower coolant line -1-. Unscrew one internal M6 Torx screw -2-, pull off line and close off bore -3-.
9.3. Loosen upper coolant line -1-. Unscrew one M6 internal Torx screw -2- and pull off line.
10. Close off bore for upper coolant line -1 - and loosen oil pressure line -2- on the turbocharger. Unscrew one M6 internal Torx screw -3-, pull off line and close off bore.
11. Remove turbocharger on cylinder bank 1-3.
12. Slide oil pressure line -1- past the turbocharger holder and then guide it out in an upward direction from the engine compartment side.
13. Replace the O-rings on all lines and clean the connections.
CAUTION:
Risk of dirt getting into turbocharger bores.
- Risk of damage to turbochargers.
- Carefully clean connection bores.
- Do not use compressed air as this can block the lubrication bores.
14. Make sure to check the connection bores on the turbocharger for dirt and clean them if necessary.
Removing oil pressure line - cylinder bank 4-6
1. Remove cover plate. Unscrew two M6 Torx screws and take off cover plate.
2. Loosen holding clamp -2- for oil pressure line -1- on the camshaft housing cover. Unscrew one M6 Torx screw.
2.1. Disconnect ignition coil plug for cylinders 4 and 5 -3-.
2.2. Disconnect cable plug for hall sender -4-.
3. Remove ignition coil for cylinder 5. Unscrew two internal M6 Torx screws and pull off ignition coil.
4. Loosen oil pressure line -1- on cylinder head 4-6.
4.1. Unscrew one internal M6 Torx screw -2-, pull off line and close off bore immediately.
CAUTION:
Mixing fluids
- Risk of damage to components
- Close off all openings immediately after exposing them (with adhesive tape, suitable stoppers).
5. Loosen three lines on the turbocharger. Close off bores immediately after pulling off a line -1-.
- Item 1: Supply line to turbocharger oil tank.
- Item 2: Lower coolant line.
- Item 3: Upper coolant line.
6. Loosen oil pressure line -2- on the turbocharger. Unscrew one M6 internal Torx screw, pull off line and close off bore.
7. Remove turbocharger on cylinder bank 4-6.
8. Guide out oil pressure line.
9. Replace the O-rings on all lines and clean the connections.
CAUTION:
Risk of dirt getting into turbocharger bores.
- Risk of damage to turbochargers.
- Carefully clean connection bores.
- Do not use compressed air as this can block the lubrication bores.
10. Make sure to check the connection bores on the turbocharger for dirt and clean them if necessary.
Installing oil pressure line
Installing oil pressure line - cylinder bank 1-3
1. Guide in oil pressure line.
1.1. Protect the sealing flanges of the oil pressure line from damage with a plug.
1.2. Do not remove plugs until just before fitting.
2. Apply a light coating of Kluber Syntheso Glep on the bore for the oil pressure line on the turbocharger.
3. Install turbocharger - 213019 Removing and installing turbocharger.
NOTE:
- Lightly grease the O-rings on the three outer lines on the turbocharger using Kluber Syntheso Glep only.
- The O-rings on the oil pressure lines must not be greased. Only apply a light coating of Kluber Syntheso Glep on the bore in the turbocharger.
- We recommend that you use the following tools to secure the internal Torx screw (oil pressure line) on the turbocharger:
- Torx screwdriver insert bits Nr.41 (Hazett 2223 lg T30).
- Change-over ratchet insert bit Nr. 186 (Hazett 6408).
- Torque wrench Nr.90 Pos.2.
4. First fit the oil pressure line on the turbocharger. Then fit the M6 internal Torx screw by hand and tighten it.
- Tightening torque: 10 Nm (7.5 ftlb.)
5. Remove plugs on the coolant lines before fitting to allow remaining coolant to drain away.
6. Fit the other three lines on the turbocharger with new O-rings.
- Tightening torque: 10 Nm (7.5 ftlb.)
7. Fit and tighten upper M6 screw -2- on oil pressure line -1-.
- Tightening torque: 10 Nm (7.5 ftlb.)
7.1. Tool recommendation: Vi-inch ratchet, long extension, joint and Torx insert T30.
8. Fit ground strap on camshaft housing cover and rubber-coated holding clamp for oil pressure line.
8.1. Fit and tighten one M6 Torx screw on each -2 and 3-.
- Tightening torque: 10 Nm (7.5 ftlb.)
9. Connect cable plug on ignition coil for cylinder 1, hall sender and valve lift adjustment valve.
10. Fit cover plate. Fit and tighten two M6 Torx screws.
- Tightening torque: 10 Nm (7.5 ftlb.)
11. Install solenoid hydraulic valve for camshaft adjustment. Pay attention to installation position.
11.1. Check O-ring and replace if necessary.
11.2. Fit and tighten two M6 Torx screws.
- Tightening torque: 10 Nm (7.5 ftlb.)
11.3. Connect cable plug on camshaft adjustment valve.
12. Position intake manifold on support in the engine compartment.
13. Connect vacuum line for the brake booster and clip in grey circlip.
Installing oil pressure line - cylinder bank 4-6
1. Guide in oil pressure line.
1.1. Protect the sealing flanges of the oil pressure line from damage with a plug.
1.2. Do not remove plugs until just before fitting.
2. Apply a light coating of Kluber Syntheso Glep on the bores for the oil pressure line on the turbocharger and cylinder head.
3. Install turbocharger.
NOTE:
- Lightly grease the O-rings on the three outer lines on the turbocharger using Kilober Syntheso Glep only.
- The O-rings on the oil pressure lines must not be greased. Only apply a light coating of Kilober Syntheso Glep on the bore in the turbocharger.
4. First fit the oil pressure line on the turbocharger, then on the cylinder head.
NOTE:
We recommend that you use the following tools to secure the internal Torx screw (oil pressure line) on the turbocharger:
- Torx screwdriver insert bits Nr.41 (Hazett 2223 lg T30).
- Change-over ratchet insert bit Nr. 186 (Hazett 6408).
- Torque wrench Nr.90 Pos.2.
4.1. Fit the M6 internal Torx screws by hand and tighten them.
- Tightening torque: 10 Nm (7.5 ftlb.)
5. Remove plugs on the coolant lines before fitting to allow remaining coolant to drain away.
NOTE:
- Lightly grease the O-rings on the three outer lines on the turbocharger using Kluber Syntheso Glep only.
- The O-rings on the oil pressure lines must not be greased. Only apply a light coating of Kluber Syntheso Glep on the bore in the turbocharger.
6. Fit the other three lines on the turbocharger with new O-rings.
- Tightening torque: 10 Nm (7.5 ftlb.)
7. Install ignition coil for cylinder 5. Fit and tighten two M6 internal Torx screws.
- Tightening torque: 10 Nm (7.5 ftlb.)
8. Fit holding clamp -2- for oil pressure line -1- on the camshaft housing cover. Fit and tighten one M6 Torx screw.
- Tightening torque: 10 Nm (7.5 ftlb.)
8.1. Connect ignition coil plug for cylinders 4 and 5 -3-.
8.2. Connect cable plug for hall sender -4-.
9. Fit cover plate. Fit and tighten two M6 Torx screws.
- Tightening torque: 10 Nm (7.5 ftlb.)
Subsequent work
1. Replace O-rings on the relevant intake manifold and grease lightly with Kluber Syntheso Glep.
2. Fix intake manifold in place on the support in the engine compartment and then fit it on the turbocharger flange.
2.1. Cylinder bank 1-3: fit and tighten two M6 Torx screws -arrows-on the turbocharger and one M6 hexagon nut -1- on the guide plate.
2.2. Connect cable plug on electronic adjuster.
2.3. Cylinder bank 4-6: Fit and tighten two M6 Torx screws -arrows-on the turbocharger.
2.4. Connect cable plug -1- on electronic adjuster.
- Tightening torque: 10 Nm (7.5 ftlb.)
3. Install rear silencer.
4. Install charge air cooler.